System of supporting turbine diffuser outlet

ABSTRACT

A system includes a diffuser section comprising an outer barrel, an inner barrel, a seal interface, and an aft plate, where the outer barrel and the inner barrel are disposed about a turbine axis, and the diffuser section is configured to receive an exhaust gas from a gas turbine. The seal interface is disposed at a downstream end of the inner barrel between the inner barrel and the aft plate. The seal interface includes a first circumferential groove configured to receive the aft plate, where the first circumferential groove opens in a first direction away from the turbine axis.

BACKGROUND

The subject matter disclosed herein relates to gas turbine engines, suchas an improved diffuser section.

Gas turbine systems generally include a compressor, a combustor, and aturbine. The compressor compresses air from an air intake, andsubsequently directs the compressed air to the combustor. The combustorcombusts a mixture of compressed air and fuel to produce hot combustiongases directed to the turbine to produce work, such as to drive anelectrical generator.

Traditional diffuser sections of the turbine are subject to highstresses due to the configuration of the diffuser section and hightemperatures associated with the exhaust gases. Accordingly, traditionaldiffuser sections experience high stresses, thereby increasing the wearon the diffuser section.

BRIEF DESCRIPTION

In one embodiment, a system includes a diffuser section including anouter barrel, an inner barrel, a seal interface, and an aft plate, wherethe outer barrel and the inner barrel are disposed about a turbine axis.The diffuser section receives an exhaust gas from a gas turbine. Theseal interface is disposed at a downstream end of the inner barrelbetween the inner barrel and the aft plate. The seal interface includesa first circumferential groove configured to receive the aft plate,where the first circumferential groove opens in a first direction awayfrom the turbine axis.

In one embodiment, a system includes a diffuser section including anouter barrel, an inner barrel, a seal interface, and an aft plate, wherethe outer barrel and the inner barrel are disposed about a turbine axis.The diffuser section receives an exhaust gas from a gas turbine. Thesystem include an exhaust plenum disposed downstream of the diffusersection, where the exhaust plenum is configured to receive the exhaustgas from the diffuser section; and the seal interface is disposed at adownstream end of the inner barrel between the inner barrel and the aftplate. The aft plate includes a plurality of circumferential segments.The seal interface includes a first circumferential groove configured toreceive the aft plate, where the first circumferential groove opens in afirst direction away from the turbine axis.

In one embodiment, a method includes inserting a plurality of aft platesegments in a radial direction towards a turbine axis into a firstcircumferential groove of a first seal interface on an inner barrel of adiffuser section of a gas turbine, interfacing the plurality of aftplates with a root of the first seal interface at a 12 o'clock positionprior to joining the aft plates, where a 6 o'clock position of the aftplate is offset from the root, and joining the plurality of aft platesegments to one another, where the aft plate segments include aplurality of stress relieving features at an end portion proximate to aseal interface.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a turbine system having aturbine that includes a modified diffuser section;

FIG. 2 is a detailed diagram of the diffuser section of the turbinedisposed within an exhaust plenum;

FIG. 3 depicts the modified upper portion of the diffuser;

FIG. 4 depicts a cross-sectional view of the diffuser taken through thebrackets along line 4-4 of FIG. 2;

FIG. 5 depicts a perspective view of the lap joint and the discretebracket, along line 5-5 of FIG. 4;

FIG. 6 depicts a perspective view of the lap joint and the discretebracket, along line 5-5 of FIG. 4;

FIG. 7 depicts an axial cross sectional view of the circumferentialgroove within the aft plate of the diffuser;

FIG. 8 depicts a cross-sectional view of the aft plate of the innerbarrel taken along line 8-8 of the diffuser;

FIG. 9 describes a method of forming the aft plate according to anembodiment of the present disclosure;

FIG. 10 depicts a perspective view of the outer barrel of the diffusersection;

FIG. 11 depicts a perspective view of the inner barrel of the diffusersection;

FIG. 12 illustrates exemplary equipment used to machine the inner barreland the outer barrel; and

FIG. 13 illustrates a method of forming the inner barrel and the outerbarrel by a spinning process.

DETAILED DESCRIPTION

A system and methods for improving traditional diffuser sections throughutilization of mechanical improvements on the diffuser section isdescribed in detail below. The mechanical improvements to the diffusersection contribute to improved mechanical integrity of the diffuser byreducing stresses associated with a traditional diffuser design. Asdiscussed in detail below, the embodiments of the mechanicalimprovements include manufacturing a desired curvature of the diffusersection, disposing a plurality of poles between a forward plate and theaft plate of the diffuser, a circumferential groove disposed in theinner barrel to receive the aft plate, a circumferential lap joint ofthe outer barrel, a plurality of discrete brackets disposed along theinner barrel and/or the outer barrel of the diffuser configured tocouple the diffuser to the turbine outlet, or any combination thereof.The curvature of the diffuser section is implemented by a machineprocess, such as a spinning process. The spinning process involvesmolding a suitable material (e.g., stainless steel, metal) for the innerbarrel and the outer barrel into the desired shape (e.g., curved) byplacing the material over a mold. The material is then molded into thedesired shape by utilizing a roller to press the material into the mold,thereby gradually forming the desired mold shape. To reduce any residualstresses encountered via the spinning process, the inner and outerbarrels may be formed from various axial segments (e.g., first pluralityof axial segments, second plurality of axial segments). Utilizing axialsegments to create the inner barrel and the outer barrel may requireless deformation of the material to create the desired shape of theinner barrel and the outer barrel, thereby contributing to reducing theamount of residual stresses that occur.

Once the axial segments (e.g., first plurality of axial segments, secondplurality of axial segments) of the inner barrel and the outer barrelare formed, the axial segments of each respective barrel may be joinedtogether. The axial segments may be cut to ensure the axial segments(e.g., first plurality of axial segments, second plurality of axialsegments) have excess material so that the segments can be adequatelyjoined together. The axial segments by be joined together by welding,brazing, fusing, bolting, fastening, or any combination thereof.

The poles are disposed between the inner barrel and the outer barrel,which are in turn disposed around the turbine axis. The poles serve tocouple the downstream end of the aft plate to the downstream end of theforward plate via the plurality of poles and are circumferentiallyspaced about the turbine axis. In some embodiments, the poles havevarying pole diameters. The pole diameter is based in part on thecircumferential location of the pole location along the diffuser (e.g.,the outer aft plate, the inner aft plate). For example, the diameter ofthe poles nearest a top portion of the diffuser (e.g., the outer aftplate, the inner aft plate) may have a larger diameter than the polesnearest a bottom portion of the diffuser. In some embodiments, the polediameters are smaller due to their proximity to flow of the exhaustgases. As such, smaller pole diameters may be beneficial by reducingblockage of the exhaust flow path due to the smaller diameters. Thepoles disposed within the top portion of the diffuser section may beconfigured to support the load (e.g., weight) of the diffuser section,such as during installation. For example, the poles disposed within thetop portion of the diffuser section may be utilized to lift the diffusersection. In some embodiments, the poles disposed within the top portionof the diffuser section may be coupled to a hoist, lift, crane, or othersuitable lifting machine to translate the diffuser section to a suitablelocation (e.g., translation for installation, removal, service, repair).The poles may reduce vibration between the inner barrel and the outerbarrel. The arrangement of the poles depends in part on the diameters ofthe poles. The poles nearest the top portion of the diffuser have largerdiameter to bypass vortex shedding frequencies where the velocity of theexhaust gases is more uniform.

The circumferential groove is located at an end of the inner barrel. Theaft plate may be inserted into the circumferential groove, such that theaft plate interfaces with portions of the root of the circumferentialgroove. The circumferential groove may reduce stress by enabling the aftplate to move within the circumferential groove. The hoop stresses maybe reduced in the region by enabling slight movement between thesections (e.g., the aft plate and the circumferential groove). Thestress reduction from implementing the circumferential groove may reducehoop stresses by as much as one-half relative to a diffuser without thecircumferential groove.

The circumferential lap joint is disposed between the downstream end ofthe outer wall of the turbine outlet and the upstream end of the outerbarrel of the diffuser section. The circumferential lap joint isconfigured to facilitate axial movement of the outer barrel relative tothe outer wall, thereby relieving stress in the outer barrel. Anupstream lip (e.g., outer lip) of the outer barrel may be disposedradially within a downstream lip (e.g., lip) of the outer wall tofacilitate ease of axial movement of the lap joint. The stress reductionby use of the upstream lip and the downstream lip of the circumferentiallap join may be further increased by the use of discrete brackets. Thediscrete brackets may be coupled to the outer barrel and a frameassembly (e.g., exhaust frame). The discrete brackets (e.g., outerbarrel discrete brackets) are configured to support the outer barrel inthe axial direction. A subset of the discrete brackets (e.g., discreteinner brackets) may be disposed circumferentially around the innerbarrel of the diffuser. The discrete inner brackets (e.g., the innerbarrel support brackets) may hold the diffuser (e.g., inner barrel) inplace and reduce movement in the axial direction. The movement of thediffuser (e.g., the inner barrel and the outer barrel) relative to theturbine outlet may be reduced and/or restrained depending on where thelap joint and discrete bracket are disposed along the outer barrel.

Turning now to the drawings and referring first to FIG. 1, a blockdiagram of an embodiment of a gas turbine system 10 is illustrated. Thediagram includes a fuel nozzle 12, fuel 14, and a combustor 16. Asdepicted, fuel 14 (e.g., a liquid fuel and/or gas fuel, such as naturalgas) is routed to the turbine system 10 through the fuel nozzle 12 intothe combustor 16. The combustor 16 ignites and combusts the air-fuelmixture 34, and then passes hot pressurized exhaust gas 36 into aturbine 18. The exhaust gas 36 passes through turbine blades of aturbine rotor in the turbine 18, thereby driving the turbine 18 torotate about the shaft 28. In an embodiment, a modified diffuser 38 iscoupled to the turbine 18. The turbine 18 is coupled to a turbineoutlet, where the turbine outlet and the diffuser 38 are configured toreceive the exhaust gases 36 from the turbine 18 during operation. Asdiscussed in detail below, embodiments of a turbine system 10 includecertain structures and components within the diffuser 38 that improvethe reliability associated with manufacturing the diffuser 38 (e.g., byreducing stress). Embodiments of the turbine system 10 may includecertain structures and components of the diffuser 38 to improve theproduction time of the diffuser 38. The exhaust gas 36 of the combustionprocess may exit the turbine system 10 via the diffuser 38 and theexhaust outlet 20. In some embodiments, the diffuser 38 may include acircumferential groove 40, one or more lap joints 42, one or morediscrete brackets 44, one or more poles 46 disposed between an aft plate62 and a forward plate 64 of the diffuser 38, or any combinationthereof. The rotating blades of the turbine 18 cause the rotation ofshaft the 28, which is coupled to several other components (e.g.,compressor 22, load 26) throughout the turbine system 10.

In an embodiment of the turbine system 10, compressor vanes or bladesare included as components of the compressor 22. Blades withincompressor the 22 may be coupled to the shaft 28 by a compressor rotor,and will rotate as the shaft 28 is driven by the turbine 18. Thecompressor 22 may intake oxidant (e.g., air) 30 to the turbine system 10via an air intake 24. Further, the shaft 28 may be coupled to the load26, which may be powered via rotation of the shaft 28. As appreciated,the load 26 may be any suitable device that may generate power via therotational output of the turbine system 10, such as a power generationplant or an external mechanical load. For example, the load 26 mayinclude an external mechanical load such as an electrical generator. Theair intake 24 draws the oxidant (e.g., air) 30 into the turbine system10 via a suitable mechanism, such as a cold air intake, for subsequentmixture of air 30 with fuel 14 via the fuel nozzle 12. The oxidant(e.g., air) 30 taken in by turbine system 10 may be fed and compressedinto pressurized air 32 by rotating blades within compressor 22. Thepressurized air 32 may then be fed into one or more fuel nozzles 12. Thefuel nozzles 12 may then mix the pressurized air 32 and fuel 14, toproduce a suitable air-fuel mixture 34 for combustion.

FIG. 2 illustrates a detailed diagram of the diffuser 38 section of theturbine 18. As depicted, the diffuser section 38 may include an upperportion 52 and a lower portion 54, which are shown as separated by aventilated bearing tunnel 56. The ventilated bearing tunnel 56 maysupply a cooling flow through the turbine outlet 20 and the diffusersection 38. It may be appreciated that the diffuser 38 has asubstantially annular shape that encloses a portion of the bearingtunnel 56. The upper portion 52 of the diffuser 38 is coupled to anexhaust frame 58 and is radially disposed within an exhaust plenum 60.The exhaust gases 36 exit through the upper and lower sections 52, 54 ofthe diffuser 38 into the exhaust plenum 60. The aft plate 62 of thediffuser section 38 is also disposed in the plenum 60. The inner barrel48 may be cooler than the outer barrel 50, particularly along portionsof the inner barrel 48 further away from the turbine outlet 20 in partdue to insulation applied to the inner barrel 48. As such, the aft plate62 may absorb heat more quickly than the inner barrel 48 contributing toa thermal gradient across the diffuser 38. This thermal gradient maycause stresses in the diffuser 38, thereby affecting the mechanicalintegrity of the diffuser 38.

The mechanical integrity of the diffuser 38 may also be affected bystresses related to the attenuation length from an air foil 82 disposedwithin the diffuser 38 and a vertical joint 74 of the exhaust frame 58.The flow path of the hot exhaust gases 36 may further reduce themechanical integrity of the diffuser 38 due to the vibratory forces andtemperature effects that may fatigue the diffuser 38. Accordingly,modifications to the diffuser 38 section as described in further detailin the discussion of FIG. 3 may reduce these effects on the diffuser 38.Such modifications may include manufacturing a desired curvature of thediffuser 38 section, disposing a plurality of the poles 46 between theforward plate 64 and the aft plate 62 of the diffuser 38, acircumferential groove 40 disposed in the inner barrel 48 to receive theaft plate 62, one or more circumferential lap joints 42, a plurality ofdiscrete brackets 44 disposed along the inner barrel 48 and the outerbarrel 50 of the diffuser 38 configured to couple the diffuser 38 to theexhaust frame 58, or any combination thereof. The circumferential lapjoint 42 and the discrete brackets 44 are configured to reduce movementin certain directions (e.g., circumferentially 66, axially 76,vertically 78, laterally 80) or facilitate movement (e.g.,circumferentially 66, axially 76, vertically 78, laterally 80, radially84), depending on how the circumferential lap joints 42 and the discretebrackets 44 are positioned.

FIG. 3 depicts the modified upper portion 52 of the diffuser 38 inaccordance with the present disclosure. The diffuser 38 section may bemanufactured such that the diffuser 38 begins to curve along the innerbarrel 48 and the outer barrel 50 of the diffuser 38 at the end nearestthe turbine outlet 20. The curvature 88 of the diffuser 38 may providestructural advantages over other diffuser shapes (e.g., more linearshaped diffusers). For example, the continuous curvature 88 of thediffuser 38 may reduce structurally-created stresses by improvingaerodynamic properties of the diffuser 38 as compared to approximating adesired curvature with linear plates. As discussed in detail below, thecurvature of the diffuser 38 may be formed by a suitable process, suchas a spinning process. In some embodiments, each of the inner barrel 48and the outer barrel 50 of the diffuser 38 is formed from more than onecone. The cone may be an annular sheet formed from a suitable material,as described with respect to FIG. 11. For example, the inner barrel 48may include 2, 3, or more cone-pieces. The outer barrel 50 may include2, 3, 4, 5, or more cone-pieces. The cone-pieces may then be subject tothe spinning process so that the desired curves of the cone-pieces areformed. The respective cone-pieces are then integrally coupled together(e.g., by welding) to form an integral diffuser 38 section, as describedfurther with respect to FIG. 11. Both the inner barrel 48 and the outerbarrel 50 cone-pieces may be formed by the spinning process. The innerbarrel 48 and the outer barrel 50 may be separate pieces which may becoupled together via the poles 46.

Other turbine modifications are disposed downstream 104 of the curvedportion of the diffuser 38. For example, the plurality of poles 46 maybe disposed circumferentially 66 between the forward plate 64 and theaft plate 62 of the diffuser 38. The poles 46 may be coupled to theforward plate 64 and the aft plate 62 to by a plurality of gussets 68 tosecure the poles 46 to the forward plate 64 and the aft plate 62. Thepoles 46 are disposed circumferentially 66 between the forward plate 64and the aft plate 62. The poles 46 may serve to reduce vibratorybehavior between the forward plate 64 and the aft plate 62. The poles 46may reduce the tendency of undesirable vibration by stiffening theforward plate 64 and the aft plate 62, thereby reducing resonance duringoperation of the gas turbine 18. The poles 46 may have varying diameters70 to accommodate flow of the exhaust gases 36. For example, the regionsin the diffuser outlet nearest the bottom, inner portion of the diffuseroutlet are equipped with poles 46 that have smaller diameters 70 tominimize blockage of the exhaust gases 36.

Also downstream 104 of the curved portion of the diffuser 38 is thecircumferential groove 40. The circumferential groove 40 is disposedwithin inner barrel 48. In some embodiments, the circumferential groove40 may be disposed on the inner barrel 48 to receive the aft plate 62.The circumferential groove 40 may reduce stresses (e.g., hoop stresses)in the region that may develop due to large temperature changes. Asdescribed above, the aft plate 62 is disposed within the exhaust plenum60 such that the aft plate 62 is exposed to approximately the sameoperating temperatures as the forward plate 64. The inner barrel 48 hubmay be insulated so that portions of the inner barrel 48 are exposed tocooler operating temperatures than the aft plate 62, thereby resultingin a large thermal gradient across the inner barrel 48 and the aft plate62. As such, the resulting thermal gradient may create stresses in theregion via thermal expansion of the inner barrel 48. The circumferentialgroove 40 may reduce stress by enabling a conical plate 72 of the aftplate 62 to move within the circumferential groove 40. By enablingslight movement in the radial direction 84 between the sections (e.g.,the conical plate 72 and the circumferential groove 40), the hoopstresses may be reduced in the region. As described in detail below, thestress reduction from implementing the circumferential groove 40 mayreduce hoop stresses by as much as one-half of the stresses experiencedby a traditional diffuser without the circumferential groove 40.

The placement of the lap joint 42 and discrete brackets 44 may bepartially defined by an attenuation length 100. The attenuation length100 is defined in part by a plurality of airfoils 82 disposed within theturbine outlet 20. The airfoil 82 is disposed between an outer wall 106of the turbine outlet 20 and an inner wall 112 of the turbine outlet 20proximate to a downstream 104 end of the turbine outlet 20. A shorterattenuation length 100 from an air foil 82 to the vertical joint 74 mayincrease stresses in the vertical joint 74, compared to otherconfigurations where the attenuation length 100 may be longer. Theattenuation length 100 may help define the location where thecircumferential lap joint 42 is disposed. For example, the lap joint 42may be disposed at a distance approximately equal to the attenuationlength 100 downstream of the air foils 82. In some embodiments, theattenuation length 100 is less than approximately 12 inches. Thediscrete brackets 44 may reduce movement of the diffuser 38 such thatmovement in the axial 76, vertical 78, and lateral 80 directions arerestricted depending on where the discrete brackets 44 are disposed onthe diffuser 38. As described in detail below, the discrete brackets 44disposed along the inner barrel 48 and the outer barrel 50 may beoriented differently to hold the aft plate 62 and the forward plate 64of the diffuser 38 in place.

Turning now to the inner barrel 48, the upstream end 102 of the innerbarrel 48 of the diffuser 38 section may be coupled to the downstreamend 104 of an inner wall 112 of the turbine outlet 20 by an innercircumferential joint 114. The inner circumferential joint 114 mayinclude the plurality of discrete brackets (e.g., brackets 47). Thediscrete brackets are configured to couple the downstream end 104 of theinner wall 112 of the turbine outlet 20 to the upstream end 102 of theinner barrel 48. The inner discrete brackets 47 are configured toaxially 76 support inner barrel 48.

On the inner barrel 48, a secondary flexible seal 101 (e.g., a secondcircumferential seal) may be disposed in an opening within a secondaryflex seal groove 102. The secondary flexible seal 101 may block hotexhaust gases 36 from entering the ventilated bearing tunnel 56. Thesecondary flexible seal 101 may include one or more plate segments whichare circumferentially segmented to make a 360 degree structure that maybe bolted at a first end 103. Similar to the flexible seal 92 of theouter barrel 50, the secondary flexible seal 101 may be uncoupledopposite the first end 103 so that the secondary flexible seal 101 maybe move freely within the opening of the secondary flex seal groove 102.

FIG. 4 depicts a cross-sectional view of the diffuser 38 taken throughthe brackets 44 along line 4-4 of FIG. 2. The curvature of the diffuser38 may begin after (e.g., downstream of) the portion of the diffuser 38where the lap joint 42 and discrete brackets 44 are disposed. Asdescribed above, the lap joint 42 and the discrete brackets 44 may bedisposed circumferentially 66 around the outer barrel 50 of the diffuser38. The discrete brackets 44 may be coupled to the outer barrel 50 and aframe assembly (e.g., exhaust frame 58). The discrete brackets 44 (e.g.,outer discrete brackets 45) are configured to support the outer barrel50 in the axial 76 direction and the circumferential direction 66.

Another set of the discrete brackets 44 may be disposedcircumferentially 66 within the inner barrel 48 of the diffuser 38. Forexample, a subset of the discrete brackets 44 may include a plurality ofsupport brackets (e.g., inner discrete brackets 47). The inner discretebrackets 47 may provide vertical 78 and/or lateral 80 support for theinner barrel 48 relative to the turbine outlet 20. Both the outerdiscrete brackets 45 and the inner discrete brackets 47 may be disposedabout the outer barrel 50 in a rotationally symmetric arrangement.

The inner barrel 48 is exposed to a cooling flow that flows through theventilated bearing tunnel 56. As such, the inner discrete brackets 47disposed within the inner barrel 48 may be made of materials thatmaintain yield strength at lower temperatures (e.g., compared to ahigher temperature of the outer barrel 50). The discrete brackets 44(e.g., the inner discrete brackets 47) may hold the diffuser (e.g.,inner barrel 48) in place and reduce movement in the axial direction 76and/or the lateral direction 80. The inner barrel 48 may include abolted joint at one end 49 to fix the diffuser 38 sections (e.g., theaft plate 62 of the diffuser and the forward plate 64 of the diffuser)to the turbine outlet 20. The discrete brackets 44 and supporting pairsof relaying blocks (see FIG. 6) enable thermal growth in the radialdirection 84.

The discrete brackets 44 may be coupled to the outer barrel 50 and theinner barrel 48 in various locations. In some embodiments, the discretebrackets 44 may be disposed at a 12 o'clock position 118, a 3 o'clockposition 120, a 6 o'clock position 122, a 9 o'clock position 124, or anycombination thereof. In some embodiments, discrete brackets 44 may bepositioned at other positions (e.g., 4 o'clock, 7 o'clock) such that theplacement of the discrete brackets 44 remains discrete (e.g., notcontinuous). Moreover, the position of the discrete brackets 44 may bearranged according to the desired restraint of the outer barrel 50 andthe inner barrel 48. In other words, the plurality of outer discretebrackets 45 and the plurality of inner discrete brackets 47 may becircumferentially 66 spaced about the turbine axis 76. The outerdiscrete brackets 45 are configured to position the outer barrel 50relative to the outer wall 106 of the turbine outlet 20 to form thecircumferential lap joint 42 between the outer wall 106 of the turbineoutlet 20 and the outer barrel 50 of the diffuser section 38. Thecircumferential lap joint 42 is continuous. The movement of the diffuser38 (e.g., the inner barrel 48 and the outer barrel 50) relative to theturbine outlet 20 may be reduced and/or restrained depending on wherethe lap joint 42 and discrete bracket 44 are disposed along the outerbarrel 50. For example, when the discrete bracket 44 are disposed at the3 o'clock position 120 and/or the 9 o'clock position 124, the diffuser38 (e.g., the inner barrel 48 and the outer barrel 50) is restrained inthe axial direction 76 and in the vertical direction 78. When thediscrete bracket 44 are disposed at the 12 o'clock position 118 and/orthe 6 o'clock position 122, the diffuser 38 (e.g., the inner barrel 48and the outer barrel 50) is restrained in the axial direction 76 and inthe lateral direction 80. The discrete brackets 44 may be supported bysupport components (e.g., a pin) as described further in FIG. 6. Thesupport components may restrict movement in the circumferentialdirection 66.

FIG. 5 depicts a perspective view of the lap joint 42 and the discretebracket 44, along line 5-5 of FIG. 4. As described above, the discretebrackets 44 may be coupled to the outer barrel 50 and the frame assembly58 (e.g., diffuser frame 116). The discrete brackets 44 are configuredto support the outer barrel 50 in the axial 76 direction, and at leastsome of the discrete brackets 44 support the outer barrel in thecircumferential direction 66.

The circumferential lap joint 42 is disposed between the downstream end104 of the outer wall 106 of the turbine outlet 20 and the upstream end102 of the outer barrel 50 of the diffuser 38 section. Thecircumferential lap joint 42 is configured to facilitate axial 76movement of the outer barrel 50 relative to the outer wall 106 of theturbine outlet 20, thereby relieving stress in the outer barrel 50. Anupstream lip (e.g., outer lip 96) of the outer barrel 50 is disposedradially 84 within a downstream lip (e.g., lip 128) of the outer wall106 to facilitate ease of movement of the lap joint 42. The stressreduction by use of the upstream lip and the downstream lip is furtherincreased by the use of discrete brackets 44. The outer discretebrackets 45 limit the heat transfer from the exhaust frame 58 to theouter barrel 50. Thus, thermal expansion and contraction is likely tooccur at fewer places than with a continuous bracket interface, and thethermal stress is controlled to be primary at the brackets 45. Forexample, the diffuser 38 section may include the plurality of discretebrackets 44 disposed along the outer barrel 50 (e.g., outer discretebrackets 45) of the diffuser 38 to reduce stress in the vertical joint74 of the exhaust frame 58.

In some embodiments, a flexible seal 92 may be utilized in the lap joint42 and discrete bracket 44 assembly. The flexible seal 92 may bedisposed proximate to the upstream lip 96 of the outer barrel 50. Theflexible seal 92 may be positioned between insulation 126 disposedaround the discrete bracket 44 and a flex seal groove 94 of the outerwall 106 of the turbine outlet 20. The flexible seal 92 may include oneor more plate segments which are circumferentially segmented to make a360 degree structure that may be bolted or fastened at a first end 93.The flexible seal 92 may remain uncoupled (e.g., unbolted) opposite thefirst end 93 so that the flexible seal 92 may move freely within theflex seal groove 94 to seal a clearance space 95 between the flexibleseal 92 and an end opposite the bolted end (e.g., first end 93 offlexible seal 92). The flexible seal 92 may discourage a cooling flowfrom along an outer surface of the turbine outlet 20 (e.g., forclearance control) into the diffuser 38. A slot 98 between the outerwall 106 of the turbine outlet 20 and the outer lip 96 of the outerbarrel 50 may facilitate some axial 76 movement of the lap joint 42. Thelip 96 may radially 84 interface with the outer lip 128 of the lap joint42.

As described above, the hot exhaust gases 36 that flow through theturbine 18 and diffuser 38 are received in the exhaust plenum 60. Theflexible seal 92 may insulate a cooling flow (e.g., in the exhaustframe) from the hot exhaust gases 36 downstream 104 of the flexible seal92. A primary flow path may 130 extend from the turbine outlet 20 to adiffuser outlet of the diffuser 38 section through an interior region134 of the diffuser 38. The interior region 134 is radially 84 withinthe outer wall 106 and the outer barrel 50 between the outer barrel 50and the inner barrel 48. The diffuser outlet is configured to direct theexhaust flow 36 to the exhaust plenum 60. A secondary flow path 136 mayextend from the exhaust plenum 60 to the interior region 134 through theslot 98 between the downstream lip 128 of the outer wall 106 and theupstream lip 96 of the outer barrel 50. The secondary flow path 136 mayextend through the circumferential lap joint 42. In some embodiments,the secondary flow path 136 may include a non-zero portion of theexhaust flow 36 of the interior region 134.

FIG. 6 depicts a perspective view of the lap joint 42 and the discretebracket 44, along line 5-5 of FIG. 4. In some embodiments, the discretebrackets 44 may be supported by a pin 86 extending axially 76 through aflange 116 of the outer barrel 50, a flange 116, and a pair of relayingblocks 90. The pin 86 may be disposed through the flange 116 and therelaying blocks 90 to support the discrete bracket 44. The pin 86 isconfigured to enable movement (e.g., via sliding) in the radialdirection 84 of the outer barrel 50 relative to the respective bracket44. As described above, the plurality of outer discrete brackets 45includes the plurality of circumferential support brackets 44 (e.g., asubset of the plurality of discrete brackets). Each support bracket 44of the plurality of discrete outer brackets 45 utilizes the pin 86 toenable movement in the radial direction 84 of the outer barrel 50relative to the respective support bracket 45. The relaying blocks 90and the support bracket 47 restrict movement in the circumferentialdirection 66.

Similar to the discrete outer brackets 44, the plurality of innerdiscrete brackets 47 may include a plurality of inner circumferentialsupport brackets that each utilize a respective pin 86 to extend axially76 through respective flanges of the inner wall 112 and the inner barrel48. The pins 86 are configured to enable radial 84 movement of the innerbarrel 48 relative to the respective inner support bracket whilerestricting circumferential 66 movement.

FIG. 7 depicts an axial cross-sectional view of the circumferentialgroove 40 within the inner barrel 48 of the diffuser 38 of FIGS. 2 and3. The aft plate 62 interfaces with the inner barrel 48 of the diffuser38 at the circumferential groove 40. As described above, the innerbarrel 48 and the outer barrel 50 are disposed about the turbine axis76. The aft plate 62 is disposed at least partially within the exhaustplenum 60 and is disposed downstream 104 of the inner barrel 48.

The circumferential groove 40 may reduce stresses (e.g., hoop stresses)in the region that may form due to large thermal gradients. The aftplate 62 and the forward plate 64 are disposed at least partially withinthe exhaust plenum 60. The hub of the inner barrel 48 is insulated suchthat the inner barrel 48 hub is exposed to cooler operating temperaturesthan the aft plate 62, thereby resulting in different temperatures atthe aft plate 62 and the inner barrel 48 hub. The difference intemperatures between the aft plate 62 and the inner barrel 48 hubresults in a large thermal gradient across the hub of the inner barrel48 and the aft plate 62. The resulting thermal gradient create stressesin the region due to thermal expansion/contraction. The circumferentialgroove 40 may reduce stress by enabling a conical plate 72 of the aftplate 62 to move within the circumferential groove 40. The hoop stressesmay be reduced in the region by enabling slight movement (i.e., upstreammovement, downstream movement) between the sections (e.g., the conicalplate 72 and the circumferential groove 40). The stress reduction fromimplementing the circumferential groove 40 may reduce hoop stresses byas much as one-half. For example, the stresses in the aft plate 62region may be reduced from approximately 413 MPa when thecircumferential groove 40 is not present in the inner barrel 48 to about207 MPa when the circumferential groove 40 is present in the innerbarrel 48.

A seal interface 140 disposed at a downstream 104 end of the innerbarrel 48 and the aft plate 62 includes the circumferential groove 40.In some embodiments, the seal interface 140 is mechanically coupled(e.g., welded, fused, brazed, bolted, fastened) to the downstream end104 of the inner barrel 48. In some embodiments, the seal interface 140is formed at the downstream end of the inner barrel 48. The sealinterface 140 may include a first circumferential groove 142 and asecond circumferential groove 144. The first circumferential groove 142is configured to receive the aft plate 62. As such, the firstcircumferential groove 142 opens in a first direction 146 (e.g.,downstream 104) away from the turbine axis 76. The secondcircumferential groove 144 is configured to receive the secondaryflexible seal 101. The secondary flexible seal 101 is configured toisolate the exhaust plenum 60 from the ventilated bearing tunnel 56. Thesecond circumferential groove 144 opens in a second direction 150 (e.g.,upstream) towards the turbine axis 76.

The first circumferential groove 142 and the second circumferentialgroove 144 enable some upstream and downstream movement of the innerbarrel 48 relative to the aft plate 62, resulting in reduced stresses inthe region. In the illustrated embodiment, the aft plate 62 isconfigured to interface with a root 160 of the first circumferentialgroove 142 at the 12 o'clock position 118 of the seal interface 140. Theseal interface 140 reduces a gap at the 12 o'clock position 118 andprovides additional support for the outer barrel 50. The seal interface140 also contributes to stress reduction in the poles 70 by enabling theseal interface of the inner barrel 48 to support some of the verticalload of the aft plate 62. The aft plate 62 may be offset from the root160 of the first circumferential groove 142 at the 6 o'clock position122 (e.g., opposite of the 12 o'clock position 118) of the sealinterface 140.

The aft plate 62 may be made up of a plurality of circumferentialsegments 152 (e.g., aft plate segments, conical plate 72). One or moreof the plurality of circumferential segments 152 may include a pluralityof stress relieving features 154 disposed along a plurality of joints156 between the circumferential segments 152 of the aft plate 62, asdescribed with respect to FIGS. 8 and 9. In some embodiments, the stressrelieving features 154 may be concentrated towards an end portion of thecircumferential segments 152 (e.g., aft plate segments) proximate to theseal interface 140.

FIG. 8 depicts a cross-sectional view of the aft plate 62 of the innerbarrel 48 taken along line 8-8 of the diffuser 38. In the illustratedembodiment, the downstream end 104 of the aft plate 62 coupled to thedownstream end 104 of the forward plate 64 via the plurality of poles46. As described above, the inner barrel 48 and the outer barrel 50 aredisposed around the turbine axis 76. As such, the plurality of poles 46may be circumferentially 66 spaced about the turbine axis 76.

As described above, the aft plate 62 may be made up of the plurality ofcircumferential segments 152 (e.g., aft plate segments, conical plate72). The plurality of circumferential segments 152 may include theplurality of stress relieving features 154 disposed along the pluralityof joints 156 between the circumferential segments 152 of the aft plate62. The plurality of stress relieving features 154 may be any suitableshape to accomplish the stress relief including circular, heart-shaped,bean-shaped, or any combination thereof.

In some embodiments, the poles 46 have varying pole diameters 70. Thepole diameter 70 is based in part on the circumferential 66 location ofthe pole 46 location along the diffuser 38. For example, the diameter 70of the poles 46 nearest a top portion 172 of the aft plate 62 and theforward plate 64 have a larger diameter 70 than the poles 46 nearest abottom portion 174 of the aft plate 62 and the forward plate 64.Accordingly, a plurality of apertures 176 correspond to the plurality ofpoles 46 disposed within the diffuser 38. The apertures 176 may varybased in part on the circumferential 66 location of the apertures 176 tocouple to outer aft plate 62 and the inner aft plate 63 via theplurality of poles.

In the illustrated embodiment, a first set 178 (see FIG. 2) of poles 46disposed at circumferential 66 locations within the bottom portion 174of the diffuser 38 section may have a non-uniform axial cross-section.For example, the first set 178 of poles 46 may have an ovular,elliptical, spherical, or other non-uniform portion of the axialcross-section. The non-uniform portion of the poles 46 within the bottomportion 174 of the diffuser 38 section may enable the poles 46 toexhibit more elasticity (e.g., in the radial direction 84) than circularpoles 46, which may reduce stresses in the bottom portion 174. In someembodiments, the poles diameters 70 are smaller to reduce aerodynamiceffects on the flow of the exhaust gases 36. As such, smaller polediameters 70 may be beneficial by reducing blockage of the exhaust flowpath 36.

FIG. 9 describes a method of forming the aft plates 62 according to anembodiment of the present disclosure. The aft plate 62 may be formed bya method 190. The method 190 may include inserting (block 192) theplurality of aft plate segments (e.g., circumferential segments 152,conical plate 72) in the radial direction 84 towards the turbine axis 76into the first circumferential groove 142 of the first seal interface162 on the inner barrel 48 of the diffuser 38 section of the gas turbine17. The method 190 may include interfacing (block 194) the plurality ofaft plates 62 with the 160 root of the first seal interface 162 the 12o'clock position 118 prior to joining the aft plates 62. In someembodiments, the 6 o'clock position 122 of the aft plate 62 is offset(e.g., spaced apart radially) from the root 160. The method 190 mayinclude joining (block 196) (e.g., welding, fusing, brazing, bolting,fastening) the plurality of aft plate segments 62 to one another. Themethod 190 may further include inserting the flexible seal 158 into thesecond circumferential groove 144 of the second seal interface 164(block 198).

Returning now to FIG. 8, the poles 46 disposed within the top portion172 of the diffuser 38 may be configured to support the load (e.g.,weight) of the diffuser 38. For example, the poles 46 disposed withinthe top portion 172 of the diffuser 38 may be utilized to lift thediffuser 38. In some embodiments, the poles 46 disposed within the topportion 172 of the diffuser 38 section may be coupled to a hoist, lift,crane, or other suitable lifting machine to move the assembled diffuser38 with aft plates 62 to a suitable location (e.g., move forinstallation, removal, service, repair).

Each of the plurality of poles 46 includes a pole axis. In someembodiments, the plurality of poles 46 may be substantially parallel toa common pole axis (e.g., the turbine axis 76). It should be appreciatedthe plurality of poles 46 do not support a plurality of turning vanes.Moreover, in some embodiments, no turning vanes are disposed in thediffuser 38. Poles are positioned at or near the downstream end of thediffuser 38 to reduce vibration and to facilitate installation.

FIGS. 10 and 11 depict a side view of the inner barrel 48 and the outerbarrel 50 of the diffuser 38. As illustrated within the solid lines, theinner barrel 48 and the outer barrel 50 are curved to reduce stresses inthe diffuser 38. The curvature 88 of the inner barrel 48 and the outerbarrel 50 begins downstream of the turbine section 18. Portions of theinner barrel 48 and the outer barrel 50 are disposed within the exhaustplenum 60. FIG. 10 depicts a side view of an embodiment of the outerbarrel 50. The outer barrel 50 includes a first plurality of axialsegments 180 disposed downstream of the outer barrel 50. In theillustrated embodiment, the outer barrel 50 includes two segments (e.g.,axial segments). Though two axial segments are shown, it will beappreciated that the outer barrel may include three, four, or more axialsegments. The first plurality of outer barrel segments 180 are joinedtogether in the axial direction and form an outer barrel interface 188between each of the outer barrel segments 180. As described above,joining may include welding, brazing, fusing, fastening, or anycombination thereof. The first plurality of outer barrel segments 180includes a first continuous curve 182 that curves away from the turbineaxis 76 (e.g., from the upstream end of the outer barrel 50 to the outeraft plate 62).

FIG. 11 depicts a side view of the inner barrel 48. In the illustratedembodiment, the inner barrel 48 includes four segments (e.g., axialsegments). The inner barrel 48 includes a second plurality of axialsegments 184 disposed between the upstream end of the inner barrel 48and the seal interface 140. Though four axial segments are shown, itwill be appreciated that the inner barrel 48 may include three, four,five, six, or more axial segments 184. The second plurality of axialsegments 184 are joined together in the axial direction and form aninner barrel interface 208 between each of the inner barrel segments184. As described above, joining may include welding, brazing, fusing,fastening, or any combination thereof. The second plurality of axialsegments 184 (e.g., inner barrel segments) includes a second continuouscurve 186 that curves away from the turbine axis 76 (e.g., from theupstream end of the inner barrel 48 to the seal interface 140). As willbe appreciated, the second plurality of axial segments 184 (e.g., of theinner barrel 48) is greater than the first plurality of axial segmentsof the outer barrel 50 due to the arrangement of the inner barrel 48 andthe outer barrel 50. The curvature of the both the inner barrel 48 andthe outer barrel 50 may be further understood with respect to thediscussion of the spinning process, as described in FIG. 12.

FIG. 12 illustrates exemplary equipment used to machine the inner barrel48 and the outer barrel 50 into the desired continuous curvature, asdescribed in FIGS. 10-11. The first and the second continuous curves182, 186 (e.g., of the outer barrel, of the inner barrel) may be createdvia a suitable cold machining process, such as a spinning process. Thespinning process involves molding a suitable material 204 (e.g.,stainless steel) for the inner barrel 48 and the outer barrel 50 intothe desired shape by placing the material over a mold 206. The material204 is then molded into the desired shape by utilizing a roller 202 topress the material into the mold 206, thereby gradually forming thedesired mold shape.

The spinning process described above enables the desired curvature ofdiffuser 38 to provide required turbine engine performance (e.g.,through reduced stresses). To reduce residual stresses encountered viathe spinning process, the inner and outer barrels 48, 50 may be formedfrom multiple axial segments (e.g., first plurality of axial segments180, second plurality of axial segments 184). Utilizing more axialsegments to create the inner barrel 48 and the outer barrel 50 mayrequire less deformation of each segment to create the desired shape ofthe inner barrel 48 and the outer barrel 50, thereby reducing the amountof residual stresses that remain in the completed diffuser 38.

Once the axial segments (e.g., first plurality of axial segments 180,second plurality of axial segments 184) are formed, the axial segmentsmay be joined together. The axial segments may be cut from the suitablematerial to ensure the axial segments (e.g., first plurality of axialsegments 180, second plurality of axial segments 184) have excessmaterial so that the segments can be adequately joined together. Theaxial segments may be axially joined together by welding, brazing,fusing, bolting, fastening, or any combination thereof.

FIG. 13 illustrates a method 300 of forming the inner barrel 48 and theouter barrel 50 by the spinning process. The spinning process, asdescribed herein, may utilize a roller to spin about an axis of a moldor the mold may spin about the axis under the roller. As describedabove, the method 300 includes forming (block 302) a first plurality ofaxial forward plate segments of an outer barrel 50 by spinning asuitable material on the mold. As described above, the spinning processfor each segment involves molding a suitable material (e.g., stainlesssteel, metal) into the desired shape by placing the material over amold. The material is then molded into the desired shape by utilizing aroller to press the material into the mold, thereby gradually deformingthe material the desired mold shape. The method 300 also includesforming (block 304) a second plurality of axial aft plate segments of aninner barrel 48 by spinning a suitable material on a mold. After theaxial segments are formed, the method 300 includes joining (block 306)the first plurality of axial forward plate segments to one another toform the outer barrel 50 and joining (block 308) the second plurality ofaxial aft plate segments to one another to form the inner barrel 48.Both the inner barrel 48 and the outer barrel 50 are coupled to the gasturbine engine 18. As described above with respect to FIG. 7, acircumferential groove may be machined into the inner barrel 48.

Technical effects of the invention include improving traditionaldiffusers through utilization of mechanical improvements on the diffusersection. The mechanical improvements to the diffuser contribute toimproved mechanical integrity of the diffuser by reducing stressesassociated with a traditional diffuser design. The embodiments of themechanical improvements include manufacturing a desired curvature of thediffuser, disposing a plurality of poles between a forward plate and theaft plate of the diffuser, a circumferential groove disposed in theinner barrel to receive the aft plate, a circumferential lap joint, aplurality of discrete brackets disposed along the inner barrel and theouter barrel of the diffuser configured to couple the diffuser to theturbine outlet, or any combination thereof.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

1. A system comprising: diffuser section comprising an outer barrel, aninner barrel, a seal interface, and an aft plate, wherein the outerbarrel and the inner barrel are disposed about a turbine axis, and thediffuser section is configured to receive an exhaust gas from a gasturbine; wherein the seal interface is disposed at a downstream end ofthe inner barrel between the inner barrel and the aft plate, the sealinterface comprises: a first circumferential groove configured toreceive the aft plate, wherein the first circumferential groove opens ina first direction away from the turbine axis.
 2. The system of claim 1,comprising an exhaust plenum disposed downstream of the diffusersection, wherein the exhaust plenum is configured to receive the exhaustgas from the diffuser section, and the first flexible seal is configuredto isolate the exhaust plenum from a bearing tunnel disposed within theinner barrel.
 3. The system of claim 2, comprising a second flexibleseal disposed at an upstream end of the outer barrel, wherein the secondflexible seal is configured to isolate the exhaust plenum from a coolingchannel disposed along a turbine outlet upstream of the outer barrel. 4.The system of claim 1, wherein the aft plate comprises a plurality ofstress relieving features at an upstream end portion proximate the sealinterface.
 5. The system of claim 4, wherein the aft plate comprises aplurality of circumferential segments, wherein a set of the plurality ofstress relieving features is disposed along a joint between radialsegments of the aft plate.
 6. The system of claim 1, wherein the aftplate is configured to interface with a root of the firstcircumferential groove at a 12 o'clock position of the seal interface.7. The system of claim 6, wherein the aft plate is offset from the rootof the first circumferential groove at a 6 o'clock position of the sealinterface, wherein the 6 o'clock position is opposite the 12 o'clockposition relative to the turbine axis.
 8. The system of claim 1, whereinthe seal interface is mechanically coupled to the downstream end of theinner barrel.
 9. A system comprising: a diffuser section comprising anouter barrel, an inner barrel, a seal interface, and an aft plate,wherein the outer barrel and the inner barrel are disposed about aturbine axis, and the diffuser section is configured to receive anexhaust gas from a gas turbine; an exhaust plenum disposed downstream ofthe diffuser section, wherein the exhaust plenum is configured toreceive the exhaust gas from the diffuser section; wherein the sealinterface is disposed at a downstream end of the inner barrel betweenthe inner barrel and the aft plate, wherein the aft plate comprises aplurality of circumferential segments and, and the seal interfacecomprises: a first circumferential groove configured to receive the aftplate, wherein the first circumferential groove opens in a firstdirection away from the turbine axis.
 10. The system of claim 9, whereina plurality of stress relieving features are disposed within the aftplate along a plurality of joints between the plurality of radialsegments upstream from the seal interface.
 11. The system of claim 10,wherein the plurality of stress relieving features are circular,heart-shaped, bean-shaped, or any combination thereof.
 12. The system ofclaim 9, wherein a plurality of joints between the plurality ofcircumferential segments are welded joints.
 13. The system of claim 9,wherein the aft plate is configured to interface with a root of thefirst circumferential groove at a 12 o'clock position of the sealinterface.
 14. The system of claim 13, wherein the aft plate is offsetfrom the root of the first circumferential groove at a 6 o'clockposition of the seal interface, wherein the 6 o'clock position isopposite the 12 o'clock position relative to the turbine axis.
 15. Thesystem of claim 9, comprising a second flexible seal disposed at anupstream end of the outer barrel, wherein the second flexible seal isconfigured to isolate the exhaust plenum from a cooling channel disposedalong a turbine outlet upstream of the outer barrel.
 16. A method,comprising: inserting a plurality of aft plate segments in a radialdirection towards a turbine axis into a first circumferential groove ofa first seal interface on an inner barrel of a diffuser section of a gasturbine; interfacing the plurality of aft plates with a root of thefirst seal interface at a 12 o'clock position prior to joining the aftplates, wherein a 6 o'clock position of the aft plate is offset from theroot; and joining the plurality of aft plate segments to one another,wherein the aft plate segments comprise a plurality of stress relievingfeatures at an end portion proximate to a seal interface.
 17. The methodof claim 16, comprising assembling an exhaust plenum about the pluralityof aft plate segments and the first seal interface.
 18. The method ofclaim 16, wherein joining comprises welding, brazing, fusing, fastening,or any combination thereof.
 19. The method of claim 16, whereininterfacing the plurality of aft plates with the root of the first sealinterface comprises sliding the aft plate towards the root such that theaft plate moves within the first circumferential groove.
 20. The methodof claim 16, comprising inserting a flexible seal into a secondcircumferential groove of a second seal interface.